Warehouse operators are under pressure to grow without expanding their footprint. In this episode of The New Warehouse Podcast, Kevin Lawton speaks with John Sauer of OPEX live from MODEX 2026. The conversation explores how OPEX is approaching scalable warehouse automation through flexible goods-to-person systems, faster deployment timelines, and new automation capabilities inside existing facilities.
The discussion highlights the ways warehouses are balancing throughput, storage density, labor reduction, and flexibility in today’s landscape.
Scalable Warehouse Automation Decisions
Sauer explained that scalability has become one of the most common themes in customer conversations. As he noted, “I want to operate within my existing building. I want to invest in a technology that’ll scale and grow as I scale and grow.”
That challenge is especially important in brownfield environments. Companies want automation that increases storage density and throughput without forcing a facility relocation. OPEX is addressing that demand through flexible systems that can scale on both storage and speed fronts.
Lead times are also improving. Sauer shared that OPEX can now deliver its five-pound Sure Sort system in about three months. He also noted that goods-to-person solutions are now under a 12-month lead time. According to Sauer, “Because we can control our destiny in manufacturing and we can find efficiencies and things of that nature, we’re getting closer and closer to the quickest lead time out there for a goods-to-person technology.” He adds, “Reducing the labor, the head count for the system, is always a target for our customers.”
Sure Sort® X Expands Flexibility for Difficult Products
Sauer explains, “Customers still have a gap in the sortability of certain items.” The upgraded Sure Sort X system can manage products up to 20 pounds and process up to 2,100 units per hour. OPEX also added cleated induction belts and transport features to improve handling for spherical products. Sauer explained, “We always handle cylindrical items, but now we can handle round items.”
The system’s flexibility opens the door for additional automation opportunities, such as supporting robotic induction workflows. He explained, “You could potentially get to human-less induction.”
Precision remains critical for industries with highly variable product profiles. Sauer pointed to cosmetics as an example. He explained, “We have to be able to accurately sort an eyeliner pencil all the way up to larger tubs of facial creams.”
Infinity Pushes Density, Throughput, and Temperature Flexibility
OPEX also demonstrated new enhancements to its Infinity goods-to-person platform. The system uses a grid-based ASRS architecture that separates storage scalability from workstation scalability. As Sauer described it, “The scalability of throughput to storage grew significantly when we went to Infinity.”
The system now supports structures up to 38.5 feet tall and can carry up to 90 pounds per bin. Sauer also shared an example of the platform’s storage flexibility. He said, “You could actually have 100,000 bins in an infinity grid feeding one station.”
Another major announcement was the introduction of Tote IO functionality. The system can now eject totes from the storage structure and allow operators to work with products externally before returning them to the system. Sauer explained, “We have to eject the totes from our aisle structure and let their folks interface with it outside of our grid.”
Key Takeaways on Scalable Warehouse Automation
- OPEX is seeing increased demand for scalable warehouse automation inside existing facilities
- Sure Sort X now handles round and non-conveyable products, including bowling balls and soccer balls.
- Sure Sort X supports products up to 20 pounds and processes up to 2,100 units per hour.
- OPEX introduced a powered tote supporting ambient, chilled, and frozen inventory in the same system
- The company stated its five-pound Sure Sort solution can now ship in about three months.
- OPEX said its goods-to-person solutions are now under 12-month lead times
